Workshop manual !"!# $%#&'#()#*+#!

(4)The hydraulic jack is not suitable for working in the acid, alkaline and corrosive air places.

(5) When tightening bolt and nut by combination sleeve, do not exercise too much force, do not

exercise impacting torsion. The rotation speed shall slow down as the rotation resistance goes up to

protect screw thread. Forbid to add sleeve or torque wrench or knock it by hammer when the torsion is

over big. Do not continue with tightening when it’s already reached the rated torque, which will cause

severe damage to the wrench and also break the bolt and nut.

! Electrical system

Diagrams reading instructions

The electric diagram describes the whole working routine of each part such as the power supply,
negative pole bonding, wires connectors’ position and the relative fuse, switchers etc. It needs to fully
understand the electric diagram firstly for diagnosing and eliminating faults.

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Electric diagram example

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Wires harness layout diagram

It describes the installation and fixing position of the main wire and connector and the routine of main
wire, which helps checking and repairing circuit.

Wires layout diagram example

Symbol Name
E1 Water level sensor of diesel filter
E2 Diesel filter heater
E3 G Bonding G
E4 8 Bonding 8
E5 Condenser fan
E6 Low pitch horn
E7 Vacuum cylinder switch
E8 High pitch horn
E9 11 Horn 11
E10 Connection to wiper motor
E11 Connection to brake switch
E12 Connection to clutch switch
E13 Pressure switch
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E14 Connection to glow plug
E15 Connection to idling increase valve
E16 Start-stop device
E17 Frame fuse box
EM01 1 Connection to master wire harness 1
EM02 2 Connection to master wire harness 2
EM3 3 Connection to master wire harness 3

This manual use the electric symbol and abbreviation as below

The description way of electric diagram

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Wire color description

Wire color Code Wire color Code
Black B Orange Or
Blue Bl Pink P
Brown Br Red R
Green G Purple V
Grey Gr Yellow Y
Light green Lg White W

Wire harness code name recognition

M**—— Master wire harness assy
E**—— Engine wire harness assy
CH**—— Chassis wire harness assy
BT**—— Battery wire harness assy
FL**—— Front left door wire harness assy
FR**—— Front right door wire harness assy
R**—— Roof wire harness assy
BTGD**—— Battery cathode wire harness assy
EGD**—— Engine grounding wire harness assy

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L>Q 2

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Fuel temp. sensor Air control EGR valve

EEC01 Port 1 of Engine wire to control wire

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E02 oil-water separator sensor interface

EEC01 Port 1 of Engine wire to control wire

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anti-theft system-1

Engine anti-theft controller

anti-theft induction coil

M09 GND point interface anti-theft induction coil Engigne anti-theft cotroller

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Tyre pressure minitor system

Tyre pressure minitor system-1

TPMS controller

M12 GND point interface

M65 TPMS controller

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collision radar system

collision radar system-1

buzzer

collision radar controller

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instruction and operation
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diagnosis and test
system structure
system structure
Remote control receiving

Vehicle speed input

Output controlling vehicle electric devices

Switch amount input

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diagnosis and test
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illumination M!VacYa1032

lamp

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When the vehicle reaches the pre-set value pnq
_default
40km/h`Wif thelocking motor is unlocked and the driver
door is closedWBCM will automatically lock the doorW
_1b0.3s`laterWexecute
and then unlock front doorW
locking actionWand then if the door is detected to be still
unlockedWit will continue to attempt to lock the doorW
and it will stop attempting after 3 times if the
corresponding door is still unlocked. The auto-latching
function will not resume until the vehicle slows down to
less 40km/h.
2

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YYR alert and warning function
remote locking and set alarm
l
Only when the key is pulled out,the remote control
signal is valid
l when all doors are closed,use the remote control to
lock the door,and then the warning lamps flash
for T2(YRabaR!103s,and the alert state is set.
l when all doors are not closed,use the remote
control,and then the door will be locked, the
warning lamp wont flash,and the alert state is not
set,during which,if the key is not in the IGN switch
and the remote control is not pressed,dangerous
warning lamps flash T2(YRabaR!103) when all
doors are closed and the vehicle is in alert state; if
the key is in the IGN switch or the remote control
is pressed,dangerous warning lamps don’t flash
T2(YRabaR!103) when all doors are closed and
the vehicle is not in the alert state.

293
Workshop manual !"!# $%#&'#()#*+#!

remote-control unlocking and alert removing

Only when The key is pulled out,remote-control
signal is valid
Use the remote control to remove the
alert,and the door is unlocked,the danger
warning lamps flash T1(0.5!0.1sec)
2
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lIn warning stateWif the door or the engine hood opensW

press the LOCK button to retreat from the warning
stateWand then all doors are lockedWthe horn stop
alarmingWand the turning lamps flash onceWanti-theft
relay closesWand alert state is set again.
2

lIn warning stateWIGN switch is at ONW30s laterWthe

warning is relieved.

2
2
2
2
2

295
Workshop manual !"!# $%#&'#()#*+#!
12.code-learning function
Pull out the keyWconnect the special code-learning
device to the reserved interface of the body to let BCM
into code-learning stateWmeanwhileWturning lamp goes
on]if one valid remote control signal is receivedWthe
turning lamps goes off after three times flashingWwhich
indicates one key is done with code-learning. One key at
a timeWevery BCM only memory one keyWif a second
key is finishedWthe first key will be erasedWand if no
signal is receivedWturning lamps goes offWthe BCM
retreat from the code-learning state.

remove and mount the battery

In warning stateWdisconnect the batteryWand reconnectWthe BCM is still in warning stateWthe car keeps warninging.

lIn alert stateWdisconnect the batteryWand reconnectWthe BCM is still in alert state

lin the secondary warning stateWdisconnect the batteryWand reconnectWand the BCM is still in alert state

diagnosis and test

diagnosis and troubleshooting

When BCM failsWreferring to the pin definition aboveWinspect according to the method belowV
take the case of the parking lampV
1Z check if BCM fusesWif the fuse is normalWgo to step2]
2Z use mutimeter to check if the power supply and GND of BCM is normalWif BCM is in the
right working condition.
3Z use the mutimeter to check if the parking lamp switch pins working state meets the
definition in the table aboveWif notWcheck the wire harness and check if the switch status
is normalWotherwise go to step 3]
4Z use the mutimeter to check if the parking lamp output pins working state meets the
definition in the table aboveWif notWcheck the wire harness and check if the output status
is normalWand if wires and relays are all normalWgo to step 5]
5Z
6Z If the 3 points are all normalWplease change the BCMWand do function debugging.

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Workshop manual !"!# $%#&'#()#*+#!
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$!a2 92 2 2 2 2 2 2 2 2
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«¬~­®
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1. }¯”°±v²k

2. «³˜´µk

3. ¶³ BCM ·¸¹ºƒ»¼½¾¹¿ÀÁÂû
Ä_M6`W¶ÅÆÇÈ 7Nlmc9Nlmk

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4. }É™•·²ÊvËW«³ BCMk

«¬~­®
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1. ±və•·²ÊvËk

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2. Tighten the BCM two fixing bolts and hex flange
nuts (M6), tightening torque 7N · m ~ 9N · m.

3. Install the glove box.

4. Install the battery cable.

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Workshop manual !"!# $%#&'#()#*+#!
Specification
Parameter index
Electrical parameters Demand
Operating Voltage DC12V
Operating voltage range DC9VcDC16V
Quiescent Current 5 mA
Insulation resistance 100M_DC500V`
Transmission frequency of the remote 315MHz±0.075MHz
Reception frequency of the body controller 315MHz±100KHz
Remote distance 20M
Operating temperature at -30ºCc+85ºC
Storage temperature at -40ºCc+90ºC
Relative humidity 95%

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3. Vehicle Harness Layout

3.1 Main wiring harness assembly:
Identifying Name Identifying Name
M01 Left front door switch M39 Front washing liquid pot motor
M02 Lock controller M40 Left daytime light
M03 Ground point 16 M41 Left foglight
M04 Instrument cluster M42 Left front combination lamp
M05 Mirror heating switch M44 Cab fuse relay boxes
M06 AC Switch MFL01 Left front door harness
M07 Hazard warning switch MFR01 Right front door harness
M08 External circulation switch MR01 Main harness connected to a ceiling harness
Interface
M09 Ground point 15 ME01 The engine wiring harness 1
M10 Crowbar 1 ME02 The engine wiring harness 2
M11 Crowbar 2 ME03 The engine wiring harness 3
M12 Ground 14 M45 Heating and cooling mode switch
M13 Ground 13 M46 Cold or warm wind execution unit
M14 Air conditioning controller M47 CAN Crowbar-A
M15 Blower speed switch M48 CAN Crowbar-B
M16 Ground point 12 M49 CAN Crowbar-C
M17 Right front fog light M50 Immobilizer module

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M18 Right daytime running lights M51 Theft coil
M19 Right front combination lamp M52 Terminating resistor
M20 Right front door contact switch M54 Driver's seat belt pre-tensioners
M22 HVAC M55 Left mirror lights
M21 Cassette players M56 Right mirror lights
M23 Crowbar -3 M57 Folding mirror switch
M24 Hand brake switch M58 Multifunction steering wheel -1
M25 Driver seat belt switch M59 Multifunction steering wheel -2
M26 Ground point 17 M61 Ground 20
M27 Cigarette Lighter -1 M62 Airbag module
M28 Cigarette Lighter -2 M63 Seat heater
M29 BCM-2 M53 BCM-3
M30 BCM-1 M64 Ground 18
M31 Combination Switch -light M65 Tire pressure monitoring
M33 Ignition Switch -2 M67 The passenger front air bag
M34 Ignition Switch -1 M68 Radar Buzzer
M35 Combination Switch - Wiper M69 Glove box light -1
M37 Headlight adjustment switch M70 Glove box light -2
M38 Brake fluid level sensor M71 Glove box light
M72 Reversing radar module
M73 Fujia seat belt pretensioners
2

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2
2
"R! Engine wiring harness assemblyV
Identifying Name Identifying Name
E01 Diesel filter temperature sensor EM01 the engine wiring harness connected to the
main harness Interface -1
E02 Water separator sensor EM02 the engine wiring harness connected to the main
harness Interface -2
E03 Ground 09 EM03 the engine wiring harness connected to the main
harness Interface -3
E12 Vacuum tube EBT Power harness connected to the engine wiring
harness Interface
E13 Low-pitched speaker ECH Engine wiring harness connected to the
chassis harness Interface
E14 Air conditioning pressure switch ECH01 Engine wiring harness connected
to the chassis harness Interface
E15 high-pitched speaker EEC01 the engine harness connected to control
wiring harness interface 1

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E16 Front wiper motor EEC02 the engine harness connected to control wiring
harness interface 2
E17 Engine ECU Interface -1 EEC03 the engine harness connected to control wiring
harness interface 3
E18 Engine ECU Interface -2
E19 Ground 10
E20 Ground 11
E21 Throttle acceleration pedal E23 Clutch pedal switch -1
E24 Brake Switch
2E26 Air flow temperature sensor adapter cable
E27 generator B+
E31 Generator regulator
E32 compressor

"R" Chassis wiring harness assembly2

222222 Identifying Name

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CH01 Right rear combination lamp
CH02 Right rear license plate light
CH03 Left rear license plate light
CH04 Left rear combination lamp
CH05 Ground 01
CH06 Fuel level sensor
CH07 Reversing light switch
CH08 Odometer sensor
CH09 Reversing radar sensor on the right side
CH10 Right-middle reversing radar sensor
CH11 Left-middle reversing radar sensor
CH12 Reversing radar sensor on the Left side
CHE01 Chassis wiring harness to engine harness interface
2

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3.4 Left front door wiring harness assembly
Identifying Name
FLM01 Left front door harness connected main harness interfaces
FL02 Left front door turn signal
FL03 Left front door tweeter
FL04 Left rearview mirror
FL05 Left Front Door Motor
FL06 Left front door woofers
FL07 Left front door window main switch
FL08 Rear mirror switch
FL09 Left front door Stopper
FL10 Left front lights

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3.5 Right front door wiring harness assembly
Identifying name
FR01 Right front door Stopper
FR02 Right front door light
FR03 Right front door switch
FR04 Right front door woofer
FR05 Right front door turn signal
FR06 Right front door motor
FR07 Right front door tweeter
FR08 Right rear view mirror
FRM01 Right front door harness connected to the main harness interface
2

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3.6 Roof wiring harness assembly

Identifying name
R01 front interior dome light
RM01 Roof harness connected to the main harness interface

3.7 Power supply wiring harness assembly

Identifying Name
BTE01 Power harness connected to the engine wiring harness Interface -1
BT01 Send cabin electrical box connected to battery B+

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BT03 starter B+
BT04 Starter solenoid switch
BT07 Battery positive terminal
BT14 Rear exhaust gas temperature sensor
BT15 Differential Pressure Sensor
Negative battery wiring harness assembly
Identifying Name
BTGD01 Negative battery terminal
BTGD02 Frame Ground
2

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3.8 Ground engine wiring harness assemblyV
Identifying name
EGD01 Engine Ground
EGD02 Frame Ground
EGD03 Body Ground

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"R+2,-./01125-B4872A.03-8764/1

Harness connector removal

Always use both hands to cut off the connector.

Pulling out the wiring with one hand can make
wire connector broken. NOTE: Press the two
locking tab, then pull the plug to cut off.
2

2
2
Harness connector connection V
Firmly grasp both sides of the connector (postive and
negative),and make sure the connector pin and the pin
hole matching and aligned with each other on both
sides, carefully pressing both sides of the wiring
devices until you hear the sound crisp snap
2
2
2
Harness connector checkV
Use a circuit tester to check the continuity of the
wiring. Insert a test probe from the wire connector side.
Do not insert a test probe at the beginning of the
connector.

2
2

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2

Wire pins removalV

z The thin rod is inserted into the beginning
of the connector housing
z Press barbs (toward the connector wire
side), and pull the wire side of the
connector wire.
2
2

Wire pin insertionV

z Check whether pin barb is fully open.
z Insert the pins from the side of the
connector wire, and push them until the
pin barbs tightly fastened.
z Gently pull the wire to make the pin reset.

2
2

Harness layout precautionsV

Use the jacket or the sleeve to protect the harness to
avoid it to directly contact with sharp edges or
surfaces.
2
2
2 2

Adequate room shall be kept between the wire harness

and the holder thereof, and ethylene sleeve and clamp are
used to protect the harness, and avoid direct contact;

2
Harnesses between the engine and chassis shall be of
2 sufficient length to prevent various chafing or
damaging
320 wiring harness due to various vibrations.
Workshop manual !"!# $%#&'#()#*+#!
2

Vehicle circuit fuseV

Vehicle circuit fuse is the most common form of
circuit protection. When the overload currents run
through the circuit, the fuse is blown to prevent
strong currents from damaging other components in
the circuit.
Before replacing a fuse, first identify the cause of the
2 overload currents and resolve. The new fuse
2 amperage must be the same as the original one.
2 Otherwise, it will cause a line fire or other serious
damage to the circuit.
2

2
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2

4 Battery
Small trucks use maintenance-free batteries. Its characteristics are: a very small consumption of the electrolyte
generally without adding distilled water during the lifespan. It also has excellent shock-resistence, high
temperature-resistence, small size, and low self-discharge. It is generally twice the lifespan of the avarage battery.
4.1 Battery installation location
Battery is located just below the container.

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4.2 Battery precaustions

WarningVThe battery must be placed beyond the reach of children to prevent possible injury.

WarningVIn general, the battery produces explosive gases, if handled carelessly, could cause personal injury.
Failure to follow the relevant instructions may result in personal injury.
WarningVNever allow flames, sparks or ignition close to the battery. When the battery positive and negative
poles across the electrodes by a metal conductor (such as: metal tools, metal wire, metal accessories, etc.)
received an unexpected short time, namely the battery external short circuit occurs, it will cause arcing poles
melting and cause the melting lead alloy splashing, and even worse generate a lot of heat to cause a fire.

warningVBatteries containing sulfuric acid components must avoid contact with skin, eyes or clothing. When
you are close to the battery, your eyes shall be suitably protected to prevent acidic solution spill. When the
acid contact with skin or eyes, immediate rinse must be at least 15 minutes with water and immediate medical
attention must be sought. If accidentally swallowed acid, you must consult a doctor immediately. Otherwise, it may
result in personal injury.

Batteries contain toxic substances. Old batteries is not conducive to health and the environment.
Disposal of garbage is prohibited by the old batteries. Be sure to use legitimate local automotive waste
disposal facilities.
2

Protection: Wear protective goggles and gloves. When charging or working near battery, must be properly
protect your face and eyes, and maintain good ventilation.

Warning: Do not alone generator to charge the battery fully discharged, if only the generator charging,
charging system without additional load, in order to continuously filled with more than eight hours.

WARNING: You must first after the battery charger is connected properly, it can turn on the charger. Doing so

may result in personal injury.

WARNING: You must first shut down after the charger; the battery can only be opened from the charger. Doing

so may result in personal injury.

Note: Avoid charging the battery in the car.

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Warning: When using the charging device, you must follow the manufacturer's instructions. Doing so may

result in personal injury.

Emergency treatment: When burning, the use of live wrench or other tool, and immediately disconnect the

battery external short circuit metal conductor, not bare hand contact, and fire extinguishing material.

Prevention: battery assembly or use metal tools for troubleshooting when using a metal wire, to avoid direct

short circuit battery positive and negative column.

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4.3 Battery Maintenance

2, The battery status indicator (electric eye):

Green: the battery is fully charged, it can normally start the car.

Black: the battery power is low, you need to add power.

White: battery scrap, to be replaced.

2, Supplementary electric battery

Vehicle under condition that the car does not start with the electrical open too long and other non-normal use,
drain the vehicle and the vehicle for a long time suspended, or vehicle charging generator failure, causing the battery
will not charge properly and cause battery power loss, battery electric eye black can not even start the car, the car
battery through the charging process.

z Visual inspection before supplementary charge the battery:

Battery case rupture or leak acid battery can not be charged, identify the reason for the replacement of the battery.

End of the column ruptured battery can not charge it, identify the reason for replacement batteries.

Electric eye whitish Do not charge the battery, replace the battery.

Before the supplementary charge, cleaning end column, descaled surface.

z Recharging Cautions:

Wear safety glasses.

Charging environment to maintain ventilation at room temperature charging.

Non-smoking charging, avoiding the introduction of fire.

After charging cable, first connect the positive connection; when the charge before disconnecting, disconnect the
negative connection.

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z Battery supplementary charge:

Confirm the battery terminal post clean, well-connected charging circuit.

Charger is connected to the positive battery positive electrode, a negative electrode connected to the negative
battery charger. Never use batteries in series (24V) charge.

Selected constant 16.0V (maximum can not exceed 16.2V, exceed this limit will result in large quantities of water
electrolysis, causing the level drops, the electric eye white, battery scrap) limit 25 amps battery charger to charge
the electric eye hair green. Battery-eyed green indicating that it has fully charged

If there is no conditions with constant voltage charging , constant current can be charged according to the
following specifications:

1. Select the rated capacity of 1/8 to 1/10 amps charging current, charging voltage to reach the end but can not
exceed 16V (16V voltage is lower than the end result sometimes after being charged electric eye is still black,
but generally does not affect use). When the charger is no guarantee that the charging voltage is limited to 16V
or less, it must be monitored once every hour artificial rechargeable battery terminal voltage, otherwise it will
cause the battery due to over voltage charging dehydration affect life even failure.

2. After charging, check the battery electric eye color. Electric eye is shown in green, indicating that the battery
is fully charged. If the electric eye is black, check the charging cable is securely connected, the connection point
is clean, the charging voltage reaches 16V, and the voltages measured after 24 hours and continue to trickle
charge.

3. If it is found white electric eye, there may be electric eyes of bubbles, the bubble will be a slight shake off the
battery. If still shaking after the white (legend has electrolyte losses), the battery should be replaced.

For the condition that the battery voltage is below 11V, it may occur early supplementary charge the battery can
not be recharged into the electric phenomenon. Because of a serious loss of battery power, the proportion of
sulfuric acid within the battery is close to water, large battery internal resistance. Then you can reduce the
charging current or switching to higher power charger, battery charging with the proceeds, the proportion of
sulfuric acid rise within the battery, the battery charging current can gradually return to normal.

During charging, the battery vents occur as a lot of spray acid, should immediately stop charging and investigate
the cause.

During charging, the battery temperature is over 45 degrees, stop charging, the battery temperature dropped to
room temperature, the charging current is reduced by half, to continue charging.

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Supplementary battery charging process, once per hour electric eye condition. Battery electric eye is green,
indicating that the battery is fully charged, please stop charging.

After charging and passing the test. FIG butter recommendations at the end of the column to prevent electrolytic
corrosion phenomenon.

2, The proper use of batteries

z Battery large current discharge time should not be too long, otherwise it would plate deformation caused by
overheating or a short circuit active material loss and reduction in capacity, when you start the vehicle, each no
more than 5 seconds, start continuous interval of not less than 10 ~ 15 seconds;
z When high rate discharge meter (discharge table) detects capacity, it should not be more than 5 seconds;
z When the car is in normal driving, the batteries are generally in the charged state; but improperly adjusted
adjustment and other reasons, resulting in the generator power capacity is low, or because of the frequent start
consuming too much battery power, or because of a short circuit electrical equipment failure caused by severe
battery when the loss of electricity, should supplement the battery charging.
z Generally, When the battery after 3 months, or when the battery capacity is found less than 50%, or unable to
start, the lights dim, the speaker sound is not normal phenomenon, in addition to normal maintenance, but should
also be carried out under the car battery supplementary charge. Meanwhile, in the charging process should pay
attention to different voltage, same capacity battery can not Hunchong. Mix old and new batteries are not allowed
to use.
z It should be measured after loading the vehicle battery voltage regulator output voltage should be adjusted
between 13.8 ~ 14.8V, the recommended voltage 14.4V. Can be adjusted within this range based on vehicle usage,
if the vehicle is frequently used, likely to cause battery overcharge, it will be appropriate to reduce the voltage,
on the contrary, if the vehicle is infrequently used or often frequent starting, it will be appropriate to increase the
voltage. Winter up a bit, some summer down to prevent overcharging.
z If the vehicle long-term storage, the negative terminal of the vehicle is disconnected. In order to avoid excessive
self-discharge and severe sulfate, loss of electricity in the battery is not the case, a three-month supplementary
power. If you store the outset loss of electricity to replenish the battery power time for voltage according to the
general voltage 12.6V less need to supplement electricity.
z It is allowed discharge current exceeds the maximum battery manufacturers, this value is generally 4 ~ 5C20 (4 ~
5 times the battery capacity), prohibited the use of the short-circuit method to test whether the battery has power.

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4.4 Battery Fault Diagnosis and Testing
Fault Undesirable phenomena
Insufficient  voltage is about 12V
charge f density 1.220g / cm3 or
less
g weak start, the lights
dim, weak sound Bulldogs
h capacity test in the
yellow zone
Overcharge d battery housing wall
permanently red and yellow
(work suppository)
f separator charring or
softening
g red-brown and
electrolyte concentration
h positive electrode active
material shedding mashed
d voltage of 10V or less
Overdischarge f density (specific gravity)
1.100g / cm3
g white and electrolyte
concentration
Short circuit d voltage of 10V or less
f no voltage grid failure
g no gravity grid failure
h bubbling smoke
discharge
!"!# $%#&'#()#*+#!
Cause Analysis Approach
d vehicle controller setpoint low d vehicle controller
f power greater than the amount of setpoint low
charge f power greater than the
g start with more frequency short amount of charge
distance g start with more
h insufficient generating capacity or frequency short distance
line failure h insufficient generating
i corrosion or receiving end virtual capacity or line failure
column i corrosion or receiving
end virtual column
d vehicle regulator setpoint high d Adjust or replace
f The charging current and long regulator
time d Press the charging
g not open the plug when charging procedure Charging
g charge level is too
light, and water use after
charging
d battery charging less on the use of d replace the circuit
d lack of vehicle power, the battery regulator
long-term use d quality and quantity
g vehicle short circuit under the car while
h forget to turn off the power charging
switch g exclusion line fault
i impure electrolyte battery h turn off the switch
self-discharge serious when parking
i Replace with new
batteries
d battery drain lead assembly or d anatomical analysis
foreign objects fall into the f replacement battery
f When battery assembly plate
bending
g foot pole plate group has a burr
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i charging failure grid did h separator holes or cracks
not respond i man-made damage
Open circuit d abnormal voltage d poor welding end post d repair
instability f off bus f replacement battery
f measured voltage of 10V g wear weld open welding
or less and zero discharge h intermediate pole off
g When the charging
current can not be entered
or sound
Dosing d electrolyte odor d electrolyte impure d replace new battery
inappropriate f density (specific gravity) f high proportion of electrolysis f adjusting the density of
1.300g / cm3 or more g dense enough not charging
g dosing after about  mistakenly add water g electrolyte replacement
density 1.100g / cm3 after charging 1.400g / cm3
h light whitish liquid color acid adjustment
Plate sulfate  Low capacity battery d First insufficiently charged and a d overcharge hair
discharges long time f repeatedly charging
f battery discharge voltage f battery with liquid shelved for a method
drops fast long time was not any time to add g water therapy
g When charging bubbles electricity  replacement battery
early g battery is in liquid state deficit, a
h charging voltage rises very long exposure time group
fast and high h electrolyte density is too high
i plate surface white i electrolyte temperature is too high
granules or white Ì impure electrolyte
Electrolyte string d low voltage d battery casing string grid crack d repair replacement
grid f when the corresponding f vibration during transportation housing
through-inclined single cell g vehicle with vibration f replacement battery
electrolyte flow h ignition implosion
 boiling phenomenon i sealing lax
when discharge

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Diagnosis and Testing

1, Battery fault diagnosis

Active d bottom of the battery d car circuit regulator setpoint high d precipitate was washed
substance have too precipitate f charging current and long time with water washing, and
shedding f battery capacity is low g large discharge and long time then charging
excess g single cell wall plug and h vehicle for a long time with high f replace battery
work with permanent temperature and long time
red-brown i substandard manufacturing plate
h electrolyte reddish
brown
i electrolyte and the
electrode active material
reddish sludge off the
separator was softened state,
a negative electrode active
material softening expansion
board
Ì massive shedding
Reverse d trans-grid 8V Manufacturing Quality d new battery
polarity f anti-two grid 4V f heavy demolition
installation g overall anti -12V

Reverse d voltage was negative
polarity charge f positive and negative
side column opposite color
g contrast color plates
Battery burst d side column ignition
f positive line breakage
g shell, cover parts of a
hole or crack
d charging polarity connection error
d improper installation
f old line, thin line
g run generator failure
h spark outside intervention
i Weld end post
Ì off bus
Í off board
330
d the reverse polarity
charge of the battery
discharged
f first trickle charge,
each single cell reaction
after normal charge
g serious new battery
d fastener installation
f replace the line
g exclude generator
failure
h battery away from heat
i keep the vent flow
Ì replacement battery
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Î intermediate pole off
Ï plate fracture
Low initial d unable to start d no real connection or line failure d carefully check the line
capacity f low voltage fover custody f charging
g slow response g positive plate passivation
h oxide negative electrode plate
i separator slight penetration

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Diagnosis and Testing

Battery fault determination

Visual inspection

Checking item Causes Approach

d Battery case collision damage Replace
Damage f improper installation

d End of the column cable connector Replace

loose or poor contact
Burn

f External short circuit

d Internal short circuit Replace

Shell
f Electrolyte level is too low, the internal
Burst spark

f Vent obstruction

d Overcharge Replace
f Excessive current charge
Deform

g Vent obstruction
f External plastic shell crashing damage Replace

Battery acid leakage g Battery upside down or tilted too large

g Poor sealing
d external short circuit Replace

End of column melt loss f poor contact

g bad welding

1. Voltage Detection

Voltage 12.5V above, electric eye Normal Load test

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green
Lack battery Supplementary
12.4 ! 11V " electric eye
charge
black
d Over-discharge (electric eye black) Replace

g Short circuit (electric hair green eyes

10.5V around or under mostly)

h Break

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Diagnosis and Testing

Battery fault determination

Charging system fault diagnosis

The failure symptoms Troubleshooting Fault handling

Charging the ignition f Lamp failure. d Install the new lamp

switch in the ON position, f Generator or battery connector f Clean and tighten battery or generator
light does not file loose or oxidized, poor ground cable, coated with anti-acid grease. Check
connection the earth connection, we need to clean and
g Voltage regulator, rotor brushes or tighten
circuit failure g Eliminate open circuit
h Ignition switch failure h Install the new ignition switch
When the engine is d Drive belt slack d Re-tensioning drive belt
running, the charging f Generator connector loose or g Clean and tighten the coupling
indicator not properly oxidized, poor ground connection Check joints
extinguished f Brush can not touch rotor ring, g Brush, if necessary cleaning / release
stuck in conduction direction, the brush, and put on new voltage
wear, damage, oil and so on. regulator or replace generator
Bearings, slip ring wear, the
voltage regulator or rectifier
assembly fails
Insufficiently charged f Drive belt slack d Re-tensioning drive belt
f The solder joint defective generator f When necessary, install new or
g Regulator between the generator replacement generator voltage regulator
housing and ground connection is h Clean and fasten tabs
not good
Over charged d regulator malfunction d If necessary, install new regulator or
replace the generator
Noise during operation d bearing wear  Install the new generator
f pulley relaxation f Tighten the pulley to the specified
g belt wear torque. As the shaft is damaged, replace
the generator
g Install new belt

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4.5 Removing the battery

Loosen the negative battery mounting bolts.

Removing the negative battery connection.

Remove the battery plate.

d Loosen the nut plate battery

f Remove the battery plate

1. Loosen the negative battery mounting bolts.

Removing the negative battery connection.

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2. Remove the battery positive cable.

d Poke up battery positive sheath

d Loosen the battery positive fixing bolt

f Remove the battery positive cable

3. Remove the battery plate.

A, loosen the nut plate battery

B, remove the battery plate

4.Remove the battery from the car

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4.6 Removal and Installation
Install battery

Warning: In general, the battery produces explosive gases, if handled carelessly, could cause personal injury, and
therefore, do not allow flames, sparks or ignition was close to the battery. Failure to follow the relevant
instructions may result in personal injury.

Protection: Wear protective goggles and gloves. When charging or working near battery, must be properly
protect your face and eyes, and maintain good ventilation.

Warning: batteries containing sulfuric acid components, the need to avoid contact with skin, eyes or clothing. When
working close to the battery, your eyes shall be suitably protected to prevent acidic solution spill. Once the acid
contact with skin or eyes, immediately rinse must be at least 15 minutes with water and seek immediate medical
attention. If accidentally swallowed acid, must consult a doctor immediately. Doing so may result in personal
injury.

NOTE: Before you connect the battery grounding line, make sure all electrical systems have been shut

down to prevent damage to the vehicle's electrical system.

Do not tilt battery more than 40 degrees.

Prohibit the battery upside down or sideways placement.

Prohibit the leakage of the battery loading.

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Check the battery tray for carrying or whether a screw nut, to prevent secondary damages the battery.

Sequentially connected battery: Connect the positive battery connection after connecting the negative battery

cable.

Note: the contents of the maintenance performed as mentioned in To remove the battery, you should use this

procedure to remove the battery.

Check before installation, make sure electric eye is green.

Prohibit electric eye black battery loading.

Install without peer pillar tap, twist.

When installing the battery, ensure that all electrical accessories in the "off" position.

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4.6 Battery Installation

z Put the battery on the battery tray.

z Install battery positive connection.

 Install the battery positive cable

f Fix bolt tightening battery positive torque

(6-8) N.m

d Install battery positive sheath

z Install battery negative connection.

Fix bolt tightening battery negative torque (6-8) N.m

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4. Install the battery plate.
d Install the battery plate
 Press plate fastening nut

5. Air Conditioner
Description and Operation
5.1 Precautions
1. Refrigerant low freezing point, highly volatile, so
in order to prevent frostbite on contact with the
skin caused by phenomena such as blindness,
glasses and gloves shall be used.

2. If the refrigerant is directed into the eye or skin

contact with:
Flush the affected area with water, and shall be
subject ophthalmology and dermatology clinics. Do
not rub the eye by hand or handkerchief.2

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2 3. Operation of the refrigerant, easy place to be
ventilated.
A large number of refrigerant discharged in enclosed
areas although harmless can cause hypoxia
phenomenon.2

2 4. When operating the refrigerant, the surrounding

environment can not have moisture, dust or other
foreign
It was that these foreign substances flowing into
the air-conditioning system will be detrimental to
the system, so pay attention.

2
2
5. It needs to use refrigerant R134a.
If you use other refrigerants will adversely affect
system components.

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6. R134a refrigerant and R12 refrigerant can not be
compatible, even minimal amount can not be
mixed.

7. Operation of the refrigerant around the vehicle

should not close to fire which can ignite or items,
and the refrigerant tank is exposed to a heat source
will cause an explosion, so pay attention.

8. R134a container is high-pressure state, must not be

placed in a high temperature environment. To
check the temperature and the storage environment
meets the following 52 Ð.

2
9. The air-conditioning components in order to
prevent water, dust, water inflow, the general use
dust cover. The dust cover is removed and the
operation must be sealed after the operation.

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10. Freezer must be painted in the O-ring when install
the air conditioning system after uninstallation.
Oils, in particular screw-type joints manually
install and then use two wrenches to assemble.
Gently push the pipe connection nuts and bolts
while assembling the flanged joints.

2 11. In the air conditioning installation, when assembled

using a predetermined torque or more O-ring grip
can cause leakage of refrigerant and, therefore, to
operate in accordance with the torque.

2 12. The pipe can not be twisted.

5.2 Diagnosis and Testing

5.2.1 Operation principle

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1. Low-pressure gaseous refrigerant from the
evaporator flows through gas compressor turning
into the high-pressure and high-temperature gas,
through the condenser cooling heat pipe cooling
into high-pressure cryogenic liquid, and then after
Drier dehumidifier with the buffer, and then a more
stable pressure and flow toward the expansion
valve through the throttle down and the last to the
evaporator. In case of a low-pressure refrigerant
that is evaporated environment, absorb large
amounts of heat.
2
2

2. The cooling system high pressure side.

2 3. Low pressure side of the refrigeration system.

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4. The compression process.

5. Condensation process.

6. Throttling expansion process.

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7. Evaporation process.

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Diagnosis and Testing

5.2.2 Air distribution system description

1. The mixed flow.
External air outlet by the following:
 Dashboard outlet
 Floor outlet

2. Ventilation.
Outside air through the instrument panel outlets.
Compressor does not work.

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3. Heater.
Most of the air outlet through the floor via a small
amount of airflow defroster duct.

2 4. The refrigeration.
Compressor, air passing through the evaporator core,
from the dashboard vents blow.

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Diagnosis and Testing
5.2.3 Leak Test
1. Tools required.
R-134a air conditioning system 24 boxed dye
tracer.
General 12 V leak detection lamp.
Fluorescent dye scavenger.
Air conditioning stain syringe tool assembly.
Replace the dye cartridges.
Electronic leak detector.
Equipped with soapy water spray bottle.
2
2

2. The fluorescent leak detector.

Important note: Be sure to use an ultraviolet lamp
with dark glasses, because they can deepen the
color stain.
Fluorescent dye helps to identify leaks in the air
conditioning system parts.

2 3. The electronic leak detector.

Important note: When you test a continuous path to
ensure that will not miss any possible leaks. Are all
parts of the detection system for leakage.2

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4. Soapy water.
With a solution containing 50% water and 50%
filled with a detergent bottle.
Run the air conditioning system and soapy water
and sprayed onto the joint member.
If the leak is obvious, and the solution will appear
bubbles.
This is an ideal method for detecting leaks in the
hoses and fittings.

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Diagnosis and Testing
5.2.4 Conditioning system performance test
1. The test should be taken in direct sunlight.

2. Do not test the vehicle at the time of the

condenser airflow obstruction, for example, close
to the wall.

2 3. Set the blower motor to the highest speed.

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4. Outside air circulation mode.

22
5. Set the cooling temperature to the coldest. Knob
indication points to the leftmost

6. Open the instrument panel facing the front of the

face of the wind position open. Put the
thermometer into the center of the outlet face about
50 millimeters deep.

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7. The test is performed when idling.

8. The two front windows are closed.

9. Connect precision pressure gauge to the air

conditioning system.

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2 10. For the humidity (% RH) Exact test, when the
humidity (% RH) change, pressure and outlet
temperature will change. See this section "air
conditioning system performance table."

2 11. Turn off the engine, the reading data and

"air-conditioning system performance table"
compared. Air conditioning system normal
operation should not be much different.

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Diagnosis and Testing
5.2.5 Recollection of refrigerant
1. Put the vehicle parked in a well-ventilated place.

2. Connect refrigerant recovery machine.

2 3. Open the refrigerant recovery machines, select a

refrigerant recovery program on the control panel.

2 4. Turn on the device high side and low side of the

manual valve.

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22
5. The refrigerant will begin recovering refrigerant
and oil from the air conditioning system.
Refrigerant recovering to the tank, lubricating oil is
diverted to the removable storage tanks.

6. Refrigerant recovery machine will discharge all the

refrigerant from the air conditioning system, the air
conditioning system will be part of the vacuum
pressure of about (10 inches of mercury) about 34
kPa.

2 7. Once you reach a partial vacuum, the proposed

closure of refrigerant recovery machine and close
both manual valves, pressure reading recorded at
this time. If the degree of vacuum after 2 minutes
reading rose to positive, indicating that the
refrigerant (boiling is completed) in the filter Drier
there are still remaining, in this case, to continue
the recovery procedure until a positive pressure rise
is not obvious.

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8. Check the oil storage tanks and recycling the
recovered record number, you will need to wait
because of the air conditioning system filling the
same amount of oil.

Diagnosis and Testing

5.2.6 Air Conditioning System Performance Table
Pounds / square
Ð Ñ Kpa Pounds / square inch Ð Ñ Kpa
inch
Definition: The table lists 134a refrigerant pressure at different temperatures. For example, at 26.6 ° C (80 ° F)
room temperature, the refrigerant tank pressure reaches 595.6 kPa (86.4 lbs / sq in). If the refrigerant is heated to
51.6 ° C (125 ° F), the pressure will rise to 1278.8 kPa (185.5 lbs / sq inch). You can also reverse search that look at
different pressures, the boiling point of determining the refrigerant 134a. For example, at 188.2 kPa (27.3 lbs /
square inch) of pressure, the refrigerant R134a has a boiling point 0 ° C (32 ° F).
2 YjRj2 ma2 "+!R"2 jmR+2
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#!aRj2 #j2 !nRa2 "R+2 !YRY2 na2 ^onR"2 naRn2
#YnRn2 a2 ^"R!2 mR"2 !"Ro2 nj2 j"+Rn2 noR"2
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#Y!R!2 Ya2 oaRY2 YYRm2 !+R^2 oj2 mjjRY2 +jRa2
+R^2 Yj2 YaYR"2 Y^Rn2 "!R!2 +a2 nYoRj2 Ya^R!2
#mRm2 !a2 Y!^R"2 YoRa2 "jRa2 +j2 nojRm2 YY"R+2
#"Ro2 !j2 Y^+R^2 !YRn2 "nRn2 Yaa2 ojmR+2 Y!^R"2
#YRY2 "a2 YnmRm2 !jRm2 ^aRj2 Yaj2 +"!R"2 Y"jR!2
aRa2 "!2 YooR!2 !nR"2 ^"R"2 YYa2 YaY!RY2 Y^mRo2
YRm2 "j2 !amR!2 !+R+2 ^mRY2 YYj2 Ya+mR^2 Yj+Ra2
^R^2 ^a2 !"oRa2 "^Rj2 ^oRo2 Y!a2 YYojR!2 YnYR+2
nR!2 ^j2 !n!Rj2 "+Rj2 jYRm2 Y!j2 Y!noRo2 YojRj2
YaRa2 ja2 "a+Rj2 ^^R+2 j^R^2 Y"a2 Y"nnR"2 Y++Ro2
Y!Rn2 jj2 "^+R^2 jaRn2 maRa2 Y^a2 Yjo+Rm2 !"aRj2

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Diagnosis and Testing

5.2.7 Air Conditioning System Performance Diagnosis

1. Heater performance diagnostics.22

Steps Operation Yes No

Whether according to the instructions in the "Symptoms" or
1 Turn to 2 —
another diagnostic table to perform the diagnosis?
d start the engine.
2 f the engine idling. Turn to 3 Turn to 9
Whether the engine reaches normal operating temperature?
d the engine idling.
f Select "(Floor Air)" mode.
g Select the minimum blower speed.
3 h Select the warmest temperature setting. Turn to 7 Turn to 4
i touch sensation heater inlet and outlet hoses at the heater
core temperature.
Is the inlet hose of heater warmer than outlet hose?
d the thermometer in the center of the outlet.
f the thermometer is fixed to the heater core outlet heater
hose.
g Select the maximum blower speed.
h Select the warmest temperature setting.
4 Turn to 5 Turn to 6
i record the temperature of the following locations:
Central dashboard vents.
The heater core outlet heater hose.
Ì compare recorded temperature.
Are two temperature readings close?
d Check whether the following parts of an air-conditioned
vehicle for leaks, and repair:
Front cowl.
Internal recirculation flap.
5 Turn to 10 —
Heating, Ventilation and Air Conditioning System module
housing.
f make the necessary repairs.
Repair is complete?

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 Check the Operation of temperature damper.
6 f make the necessary repairs. Turn to 10 —
Repair is complete?
 Turn off the engine.
f back flush the heater core.
g start the engine.
h Select "(Floor Air)" mode.
7 i Select the minimum blower speed. Turn to 8 Turn to 10
i Select the warmest temperature setting.
Ì Touch the temperature inlet and outlet hoses of the
heater at the heater core.
Is the inlet hose of heater warmer than outlet hose?
Replace the heater core.
8 Turn to 10 —
Repair is complete?
Repair the fault of engine temperature too low.
9 Turn to 10 —
Repair is complete?
Operate the system and test the repair.
10 System is regular Turn to 2
Failure being found and solved?

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Diagnosis and Testing

Air Conditioning System Performance Diagnosis

Defrost insufficient.

Steps Operation Yes No

Whether according to the instructions in the "Symptoms" or
Y2 Turn to 10 J2
another diagnostic table to perform the diagnosis?
d Start the engine.
f Select "DEFROST (Defrosting)" mode.
2 Turn to 3 Turn to 10
g Select the maximum blower speed.
Is there sufficient air from the defroster outlet flows?
Measure the engine operating temperature.
3 Turn to 4 Turn to 8
Whether the engine has reached normal operating temperature?
f Select the minimum blower speed.
f Select the highest temperature setting.
4 g Touch the temperature inlet and outlet hoses of the heater at Turn to 11 Turn to 5
the heater core.
Is the inlet hose of heater warmer than outlet hose?
Test the operation of the air conditioning compressor.
5 Turn to 7 Turn to 6
The air conditioning compressor is working?
Replace the air conditioning compressor.
6 Turn to 14 —
Repair is complete?
Test air conditioning system performance.
7 Turn to 9 Turn to 12
The operation of the air conditioning system is compliance?
Repair the fault that the engine temperature is too low.
8 Turn to 14 —
Repair is complete?
Check circulation within the damper is working properly.
9 Turn to 14 Turn to 13
Internal circulation damper is working properly?
Repair the fault of the wind outlet.
10 Turn to 14 —
Repair is complete?
Repair heater failure.
11 Turn to 14 —
Repair is complete?
Repair the failure of air conditioning performance.
12 Turn to 14 —
Repair is complete?
13 Repair the fault of inside recirculation flap. Turn to 14 —
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Repair is complete?
Operate the system and test the repair.
14 System is regular Turn to 2
The failure is found and solved?

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Diagnosis and Testing

Air Conditioning System Performance Diagnosis

1. Blower motor noise diagnosis.

Steps Operation Yes No

Whether according to the instructions in the "Symptoms" or
1 Turn to 2 —
another diagnostic table to perform the diagnosis?
Check the air inlet grille for debris.
2 Turn to 8 Turn to 3
Is there debris exists?
1. Sit in the car.
2. Close doors and windows.
3. With the engine off, turn the ignition switch in the ON
3 position. Turn to 4 Turn to 11
4. Run the blower motor at all speeds and models to determine
where, when noise appears.
Blower noise during operation noticeable?
Touch the blower housing, vibration check whether the blower
4 motor is running in the respective rotational speed. Turn to 6 Turn to 5
Whether there is excessive vibration?
Listen to the voice of the blower motor at each speed.
5 Turn to 9 Turn to 11
Whether the blower motor squeak or chirp and other noise?
1. Remove the blower motor.
2. Check the blower motor impeller for foreign objects
deposition.
6 Turn to 8 Turn to 7
3. Check the blower motor of a foreign body deposition.
Whether foreign body was found on the blower motor or
blower motor wheel?
Check that the blower motor is the following situation:
Blade cracking.
7 Impeller fastener loosening. Turn to 9 Turn to 10
Impeller positioned incorrectly.
Are any of the above found faults?
Remove foreign matter.
8 Turn to 10 —
Whether to complete the operation?
9 Replace the blower motor. Turn to 11 —
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Repair is complete?
Install the blower motor.
10 Turn to 11 —
Whether to complete the operation?
Operate the system and test the repair.
11 System is regular Turn to 2
The failure is found and solved?

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Diagnosis and Testing

Air Conditioning System Performance Diagnosis

Cooling system noise diagnostics.

Steps Operation Yes No

Whether according to the instructions in the "Symptoms" or
Y2 Turn to 2 J2
another diagnostic table to perform the diagnosis?
Check the accessory drive belt and transmission belt tensioner
2 Turn to 3 —
if there is any fault, troubleshooting when necessary.
Run the engine and check if there is a noise in compressor:
3 Turn to 5 Turn to 4
The noise persists for more than 30 seconds?
Liquid hammer
noise is a common
phenomenon. This
happens when the
Run the engine for a few minutes.
system is closed
Stop for 1 minute.
4 Turn to 6 for a long time at a
Then start the engine.
higher ambient
If the noise is detected?
temperature, and
then passes
through the whole
night.
Check the system whether the refrigerant filling quantity is too
5 low. Turn to 7 Turn to 8
System refrigerant is enough?
Check whether the thermal expansion valve is stuck in the
Replace expansion
6 closed or open position. Turn to 7
valve
Thermal expansion valve is stuck in the open position?
Check if the compressor bolt and / or air conditioning line is
Fastening bolt and /
7 scraped against the body parts. Turn to 8
or re setting line
Is there a mounting bolt loose?
Recover refrigerant and replace compressor.
8 Refill the system. Check the system Turn to 1
Gas pressure is within the specified rangeÒ

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Diagnosis and testing

Performance diagnosis of air conditioning system

Noise diagnosis of air conditioning system actuator.

Steps Operation Yes No

Whether according to the instructions in the "Symptoms" or
1 Turn to 2 —
another diagnostic table to perform the diagnosis?
1. Start engine.
2.Complete all of the following settings:
Blower motor speed
Heating, ventilation and air conditioning system
Temperature control setting
2 3.Determine the type of noise: Turn to 6 Turn to 3
Scratching, thump
Tick / rattle, chirp or creak
Wind / howling
When the selection mode or temperature setting, scratching or
thuds are obvious?
When the rotation speed of the blower motor is reduced, the
3 tick / rattle, chirp, squeak or scratching still exist but the sound Turn to 6 Turn to 4
is reduced?
Whether in all modes of wind / howling are obvious, but not all
4 Turn to 6 Turn to 5
the temperature settings are the same?
If only in the defrosting or underfloor air supply mode has
5 Turn to 6 Turn to 6
obvious wind / howling?
Remove instrument panel bracket.
Check whether the normal operation of the damper.
6 Turn to 9 Turn to 7
Check whether the air duct is blocked or foreign body.
Do you find any of the above?
Check mode, temperature door and seals are warping or
7 cracking. Turn to 10 Turn to 8
The air door is in a normal state?
Replace the corresponding damper and / or seals.
8 Turn to 10 —
Repair is completed?
9 Remove a blockage or foreign matter. Repair is completed? Turn to 10 —
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Mount instrument panel bracket.
10 Turn to 11 —
Whether complete the operation?
Operate the system and test the repair.
11 System is regular Turn to 2
The failure is found and solved?

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Diagnosis and testing

Performance diagnosis of air conditioning system

1. Odor diagnosis.

Steps Operation Yes No

Whether according to the instructions in the "Symptoms" or
Y2 Turn to 2 —
another diagnostic table to perform the diagnosis?
1. Sit in the car.
2. Close all doors and windows.
3. Start engine.
4. Let the engine idling at normal operating temperature.
!2 5. Select the maximum blower speed. Turn to 3 Turn to 8
6. The selection of the most cold temperature setting.
7. The operation in all the blower speed mode and temperature,
determined to be what kind of smell (musty odor, flavor oil,
coolant).
Check the heating, ventilation and air conditioning system
"2 module assembly filter and the air inlet grille is of debris. Turn to 4 Turn to 5
Is there a scrap of debris?
Clear all debris.
^2 Turn to 15 —
Whether to complete the operation?
Check if the carpet is wet.
j2 Turn to 6 Turn to 14
Is the carpet wet?
Check if there is the following:
The front wind windows all around
Heating, ventilation and air conditioning system module drain
m2 Turn to 7 Turn to 14
plug
Door seal around the leak
Is there a leak?
Repair leaks when necessary.
n2 Turn to 15 —
Repair is completed?
o2 Does the smell have cooling liquid flavor? Turn to 9 Turn to 12
Check the cooling system for leaks.
+2 Turn to 10 Turn to 12
Is there a leak?
Ya2 Check if there is a layer of film on the car whether there is Turn to 11 Turn to 15
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coolant leakage or front windshield glass.
Does failure appear?
Replace the heater core.
YY2 Turn to 15 —
Repair is completed?
Y!2 Does it have the smell of oil? Turn to 13 Turn to 15
Check whether there is a leak in the engine compartment.
Y"2 Repair the oil leakage fault. Turn to 15 —
Repair is completed?
Musty may be caused by the accumulation in the evaporator
and the heater core or heating, ventilation and air conditioning
Y^2 Turn to 15 —
system module assembly inside the mold cause.
Whether to complete the operation?
Operate the system and test the repair.
Yj2 System is regular Turn to 2
The failure is found and solved?
2

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Diagnosis and Testing

Air Conditioning System Performance Diagnosis

Diagnosis of blower motor not work

Steps Operation Yes No

d Turned off the engine, the ignition switch in the ON
position.
Y2 Turn to“Fault 8”k Turn to 2
f Put the blower motor speed switch in each position.
Whether the blower motor speed can work in any position?
d Turn the ignition switch to the OFF position.
g Disconnect the blower motor.
h Connect a test light between blower motor supply voltage
circuit and the blower motor control circuit.
!2 Turn to 9 Turn to 3
h With the engine turned off, the ignition switch in the ON
position.
i The blower motor speed switch in each position.
Does the test light are lit at any speed?
Test the blower motor supply voltage circuit is open or the
3 resistance is too large. Turn to 15 Turn to 4
The failure is found and solved?
Test blower motor circuit is open or the resistance is too large.
4 Turn to 15 Turn to 5
The failure is found and solved?
d Turn the ignition switch to the OFF position.
f Connect the blower motor.
g Heating, Ventilation and Air Conditioning Control Module.
5 h with the engine turn off, the ignition switch in the ON Turn to 10 Turn to 6
position.
i The blower motor speed switch in each position.
Whether the blower motor speed can work in any position?
Check the serial data encoding or malfunction.
m2 Turn to 7 Turn to 8
The failure is found and solved?
Check the circuit.
n2 Turn to 15 Turn to 8
The failure is found and solved?
Test the blower motor switch control circuit is open or the
o2 Turn to 15 Turn to 11
resistance is too large.
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The failure is found and solved?
Check that the blower motor is bad.
+2 Turn to 15 Turn to 12
The failure is found and solved?
Check the Heating, Ventilation and Air Conditioning Control
Ya2 Module is bad. Turn to 15 Turn to 13
The failure is found and solved?
Check whether the entertainment system is bad.
YY2 Turn to 15 Turn to 14
The failure is found and solved?
Replace the blower motor.
Y!2 Turn to 15
Whether complete the replacement?
Replacing the Heating, Ventilation and Air Conditioning
Y"2 Control Module. Turn to 15
Whether complete the replacement?
Replace the blower switch.
Y^2 Turn to 15
Whether complete the replacement?
Operate the system and test the repair.
Yj2 System is regular Turn to 1
The failure is found and solved?

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Diagnosis and Testing

Air Conditioning System Performance Diagnosis

1. Blower Motor Fault Diagnosis.
Steps Operation Yes No
d With the engine turned off, the ignition switch in the ON
position.
Y2 Turn to 3 Turn to 2
g Blower motor speed switch in each position.
Is there any blower speed position work?
Current fuse with the
Check the blower motor fuse is blown.
2 same specifications to Turn to 3
Is fuse blown?
replace it.
Check power to the blower motor.
"2
Despite the voltage, the blower motor does not run?
 Run the blower at all speed, integrated radio control
blower control position to run again.
4 Turn to 8 Turn to 5
f It should have 20 valid blower speed.
Are all blower speed are effective?
d Insert the 2-pin connector back on the blower motor.
f using the integrated radio control blower, beginning from
the lowest speed, in 20 positions of the blower fan speed to run
again.
j2 Turn to 8 Turn to 6
g will be shown with the voltage contrast, see "Auto
Heating, Ventilation and Air Conditioning System" in "1.2.1.2
sensor resistance value table."
Voltage is close to the voltage shown?
Connection failure diagnostic. Go to the test compound, Executive blower
switch data. With a scan tool to increase / decrease softkey to switch function
m2 Turn to 7
select all of the 20 speed blower fan integrated radio
Are all speeds valid? control testing.
Replacing the Heating, Ventilation and Air Conditioning
n2 Control Module. Turn to 8
The failure is found and solved?
Operate the system and test the repair.
o2 System is regular Turn to 1
The failure is found and solved?

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Diagnosis and Testing

Air Conditioning System Performance Diagnosis

Air conditioning system cooling effect diagnosis.

Steps Operation Yes No

Check the operation of the air mixing damper to determine
Y2 that it has no blockage or rupture. Replace the actuator Turn to 2
Air mixing damper is for cracks or blocked?
 With the engine turned off, the ignitions switch in the
ON position.
!2 Turn to 3 Turn to“Fault7”
 Blower motor speed switch in each position.
Whether the blower motor speed can work in any position?
"2 Whether the blower motor is running at the appropriate speed? Turn to 4 Turn to“Fault 8”
Go to "Auto
 Start the engine.
Heating,
 Put blowing mode switch to face position.
Ventilation and Air
g Inner loop switch to "ON (ON)" position.
Conditioning
^2 Recirculation flap inside observation. Turn to 5
System" in the "air
h The inner loop switch to "OFF (OFF)" position.
circulating
If the Recirculation flap transfers within the inner loop
troubleshooting
from position to position ventilation?
assistance."
f Start the engine.
 With fault diagnostic clears Heating, Ventilation and air
conditioning systems all stored in control module
diagnostic codes. Replace the
j2 Turn to 6
 Air temperature switch to the left coldest location. compressor
h The mode switch to double-blowing position.
i The blower motor switch to the high speed position.
The air conditioning compressor is working?
Air conditioning system performance test execution.
m2 Turn to 9 Turn to 7
The failure is found and solved?
In the vicinity of a temperature sensor is installed inside the air
n2 thermometer. Turn to 9 Turn to 8
Thermometer temperature is at 3 ° C (5 ° F) or less?
o2 Check the suction pipe for leaks or blockage. Turn to 9 —
372
Workshop manual !"!# $%#&'#()#*+#!
The failure is found and solved?
Operate the system and test the repair.
+2 System is regular Turn to 1
The failure is found and solved?2

373
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Diagnosis and Testing

Air Conditioning System Performance Diagnosis

2. Heater underdiagnosed.

Steps Operation Yes No

Check the operation of the air mixing damper to determine
Y2 that it has no blockage or rupture. Replace the actuator Turn to 2
Air mixing damper for cracks or blocked?
The blower motor speed switch in each position.
!2 Turn to 3 Turn to “Fault7”
Whether the blower motor speed can work in any position?
"2 Whether the blower motor is running at the appropriate speed? Turn to 4 Turn to “Fault7”
Go to "Auto
d Start the engine.
Heating,
g Put blowing mode switch to face position.
Ventilation and Air
g Inner loop switch to "ON (ON)" position.
Conditioning
^2 Recirculation flap inside observation. Turn to 5
System" in the "air
h The inner loop switch to "OFF (OFF)" position.
circulating
If the Recirculation flap transfers within the inner loop from
troubleshooting
position to position ventilation?
assistance."
The temperature switch in the "OFF (OFF)" position.
j2 When asked when the defrost heater or, if there is too cold Turn to 6 Turn to 9
inside the vehicle?
d start the engine.
Replace the
6 f Close Heating, Ventilation, and Air Conditioning System. Turn to 8
compressor
The air conditioning compressor is working?
Check the cooling system if the following conditions exist:
Coolant level is too low.
Accessory drive belt loose or worn.
Heater radiator hoses or hose leaks.
7 Turn to 10 Turn to 8
Radiator hose kinked hose or heater.
Radiator pressure cap seal is missing.
Radiator cap leaks.
The failure is found and solved?
d will face blowing mode switch position.
o2 Turn to 10 Turn to 9
f with the engine turned off, the ignition switch in the ON
374
Workshop manual !"!# $%#&'#()#*+#!
position.
g The maximum speed blower motor switch in position.h
Insert a 5 cm (2 inches) square paper cover on the sensor inlet,
check for air flow through the interior air temperature sensor.
Paper is to stay in place?
Check the suction pipe for leaks or blockage.
+2 Turn to 10 —
Have you found out and troubleshot the malfunction?
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Diagnosis and Test2

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5.3 Removal and Installation2
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Removal and Installation

5.3.2 Remove evaporator assembly

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Removal and Installation

5.3.3 Remove air blower assembly

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Removal and Installation

5.3.4 Remove fan assembly of condensor

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Removal and Installation
5.3.5 Removal and Installation of Condensor Assembly
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5.3.6 Install Compressor Assembly
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5.3.7 Remove A/C Control Assembly
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Removal and Installation

5.3.8 Remove Expansion Valve Assembly

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